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DISCLAIMER:I DO NOT, by any means, support piracy, therefore I won't provide you with download links for free games or anything piracy-related at all. It harms publishers and developers.
Even though there are sources, this tutorial have been completely written by me. If you see it elsewhere, report it. If you want to use it completely or part of it elsewhere, PM me. Trust me, I'm cool and will most probably let you use it if you ask first =)
Also, it's a long tutorial (that's why I have put almost everything on spoiler tabs), so make sure you have free time before starting the procedure.THINGS YOU SHOULD KNOW/DO BEFORE YOU KEEP ON READING:

Warning: Spoilers inside!

I wrote this tutorial assuming you're using a USB Flash Drive with one partition only, not a hard disk drive. Also, you need to check if your USB Drive is compatible with Wii. Check it at http://wiki.gbatemp.net/wiki/USB_Devices_Compatibility_List/
If it's listed as compatible, check if it's really having problems. If it isn't listed at all, you can at least try. To do so, follow these steps:
1- Disable multi-USB port support on USB Loader GX, if it isn't already
2- Plug your "suspicious" USB Drive on the USB port 0 (Closer to the edge of the console). You must have a GC game installed to check it
3- Start USB Loader GX. If it takes longer than it should to boot, it's a sign of bad formatted USB stick
4- Last check: if your game is listed, try to run it. You'll probably get some error. If it isn't listed, go to "Hard Drive Settings" on USB Loader. Go to the game/install partition and press A. If it changes the partition, it's integrity is screwed up. So read on

This tutorial will (most likely) help you with the following problems:

Warning: Spoilers inside!

-apploader size is zero
-al error app_entry is not within the apploader area
-Games that have been reported to work freezing at random points or showing messages like "An error has occurred. Turn the power off and refer to the Nintendo GameCube Instruction Booklet for further information"

It's very easy to get your drive working. Just follow everything as I say and it should be OK. I have tested it with a Kingston DT101 II and a generic USB drive (both 4gb) and they worked fine.CMD Steps:

Warning: Spoilers inside!

NOTE: it's quite obvious, but on CMD you must type the commands without quotes, and hit enter to actually use it
1st step: start CMD as administrator, use the "DISKPART" command
2nd step: use the "List disk" command
3rd step: check the number that representes your USB drive, type "select disk X" (where X is your drive number) and hit enter. pay CLOSE attention on this step so you won't select the wrong drive
4th step: use the "clean" command
5th step: use the "clean all" command
"Wait a minute, why can't I just use the 'clean all' command?" I tried and it just gave me an "Access denied" error, but you're free to try it
6th step (OPTIONAL): If you've never used CMD before, wait about 3 seconds after hitting anter for the "clean all" command and type anything (your name will do) BUT DON'T hit enter. It's not really necessary, but after DISKPART finishes it's job (which, by the way, may take some time), a new line will appear with what you've written in the end. When it happens you can close CMD

EaseUS Steps:

Warning: Spoilers inside!

NOTE: follow everything exactly as stated here, so you won't end up screwing your USB device again
1st step: open up EaseUS Partition Master Free Edition and select Partition Manager
2nd step: your USB drive will be listed at the bottom of the program, and will be shown as Unallocated. Right-click it and select "Create Partition"
3rd step: Change the following options:
-Partition Label: You're free to label it whatever you want. Mine is labeled GC.
-Create as: You must be 140% sure it's set to Primary
-Drive Letter: You're free to select it too. I randomly selected N:, now whenever I plug my USB drive it is show as GC(N
-File System: You must select Fat32
-Note that the cluster size option will disappear after you select Fat32 as file system. No need to worry, just click OK.
4th step: A new pop-up will be presented, where you can set size and position. Use all the available space so that "Unallocated space before" and "Unallocated space after" say 0.0 MB, and then click OK (AGAIN, assuming it's an USB Flash Drive up to 32gb)
5th step: Right-click your USB drive, click "Advanced", then select "Set Active". A window will pop-up telling you that setting the partition to Active will make other primary partitions inactive. Just click OK
6th step: click "Apply" on the left upper corner. After it's done, a new pop-up will come, saying that the operations have been completed succesfully.

Finishing:

Warning: Spoilers inside!

Now install a GC game on the USB drive. I recommend using DMToolbox 0.3 by Crediar. After it's installed, plug the USB drive on your Wii, boot USB Loader GX (it should not take too much time now), hook up your GameCube Controller, start your game and be happy

For some reason it wouldn't appear on the original post, so here it goes. If you have any doubt, feel free to ask and I'll reply as soon as possible. Just DON'T PM me with doubts, your problem/solution may be the same or at least similar for somebody else, so I won't have to reply the same things multiple times. Thanks for reading my first guide here, and please answer the poll =) Oh, and sorry about the misspelling at the thread title. Almost 2 A.M and I still didn't sleep

Also keep in mind that some HDDs simply will NOT work. One of my drives always gets an apploader size is zero message, whereas my 1TB drive works perfectly fine.

Click to expand...

I don't know, I would have thought the same thing until this thread fixed it for me. I agree that some HDD won't work, but usually I think they would be unable to get to the splash screen at all in that case.

Well, I think if your HDD works for Wii games it should work with Dios Mios. My flash drives were giving me the same error.. Games freezing, apploader size is zero, while Wii games were just perfect! It didn't matter how many times I would format it through Windows, Quick Format, Fat32 Formatter... Everytime the same thing. The only thing that helped me was what's written on my guide. It's like ''factory resetting'' a HDD. I'll tell you the same thing I told Nicholas.. Everything is worth a try.. Of course, if you want to use DM. If you don't want to, just keep it the way it is

Well, I think if your HDD works for Wii games it should work with Dios Mios. My flash drives were giving me the same error.. Games freezing, apploader size is zero, while Wii games were just perfect! It didn't matter how many times I would format it through Windows, Quick Format, Fat32 Formatter... Everytime the same thing. The only thing that helped me was what's written on my guide. It's like ''factory resetting'' a HDD. I'll tell you the same thing I told Nicholas.. Everything is worth a try.. Of course, if you want to use DM. If you don't want to, just keep it the way it is

Click to expand...

Hmm, I suppose it's very possible that I did something wrong, then. I did the same thing for both drives, but only the 1TB worked for whatever reason. Oh well. At least I can play my beloved GC games.

I was having the appoader size is zero on one of my drives and I found this guide. Followed every step and now Im playing with my 60GB fujitsu drive again. Maybe that drive was ''dirty'' as hell... many traces maybe who knows. The CMD part is helpful I didnt know the clean and clean all commands. I tought one of my drives was rejecting Dios Mios or Nintendont.

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